KR20130113933A - Panel and methods for manufacturing panels - Google Patents

Abstract

A panel of a type comprising at least a substrate and a top layer provided on the substrate, wherein the top layer comprises a vinyl-based composite material layer, wherein the substrate is a wood-based substrate and a primer is provided between the substrate and the vinyl-based composite material layer. It is characterized by.

Description

PANEL AND METHODS FOR MANUFACTURING PANELS}

The present invention relates to a panel and a method for manufacturing the panel.

More particularly, the invention relates to a panel of the type comprising at least a substrate and comprising a top layer provided on the substrate, the top layer comprising a printed pattern and a transparent or translucent synthetic material layer provided on the printed pattern. Include. Here, this may relate to, for example, furniture panels, ceiling panels, floor panels, etc., consisting essentially of MDF or HDF (medium density or high density fiberboard) base panels or substrates and top layers provided thereon. According to a first possible embodiment, the present invention provides a substrate in which one or more layers of material are provided, wherein at least one of the layers of material is carried out directly on the substrate, which print is then at least one of the printed fringes. It relates to a panel obtained by a method of forming a part. According to a second possible embodiment, the invention provides a sheet of material in which one or more layers of material are provided on a substrate, at least one of the layers of material comprising a print of the sheet of material then at least a portion of the printed pattern. It relates to a panel obtained by a method of forming a.

Panels made according to the above first possible example for panels are thus known, for example in US 1,971,067 or DE 195 32 819 A1. From that document, the material layer may comprise one or more primer layers, which may comprise one or more finishing layers extending substantially below the print and / or substantially extending above the print. It is also known. Such a finishing layer may comprise, for example, a transparent or translucent synthetic material layer that forms a protective layer over the printed ornament and may include wear resistant particles such as, for example, aluminum oxide. It is not excluded that this protective layer includes a sheet of material such as a paper sheet.

Background art relating to panels with prints performed directly on the substrate is also further described in WO 01/48333, WO 02/00449, WO 2004/042168, EP 1 454 763, DE 197 25 829 C1 and DE 10 2004 009 160 A1. Becomes clear.

Above all, it is known from WO 01/48333 that either lacquer or synthetic resin can be applied to realize the material layer. In the case of a synthetic resin, it is applied through a carrier sheet which is provided with this synthetic resin in advance and provided to the substrate by a heated press. In the case of lacquers, for example, UV curing lacquers can be applied. Each, also wear resistant particles, is applied to obtain sufficient wear resistance at the surface of the panel. However, such wear resistant particles reduce the transparency of the material layer.

First of all, it is known from DE 197 25 829 C1 or EP 1 454 763 that one or more synthetic resins applied in the liquid state can be used to realize the material layer. After this resin layer is dried, it is cured in a hot press. By this method, an upper layer without paper can be realized. According to the background, the attachment of the synthetic resin is only possible in water-based inks. However, aqueous inks are less resistant to UV based inks, for example against UV radiation due to sunlight.

Panels made according to this second possibility for panels are known, for example, from WO 97/47834 and WO 01/96689. Such panels typically comprise an upper layer provided over the substrate and based on the thermosetting resin, which is composed of a sheet of paper with the resin by press treatment. One of these paper sheets usually has a printed pattern, while the other paper sheet is transparent and serves as a protective layer for this printed pattern. During the press treatment, relief can also be realized on the surface of the transparent or translucent layer.

The present invention aims to provide an alternative panel and method in the first example, according to another independent aspect thereof, which panel and method are more smoothly than the method of the background according to its various preferred embodiments. And / or economically. The panel of the present invention according to another embodiment of the present invention also exhibits mechanical or optical properties, which means development for panels known in the background. For example, when the panel is used as a floor panel, it is possible to obtain a panel which causes a more acceptable sound and / or a more pleasant and warmer feeling.

To this end, the invention relates, in accordance with its first independent aspect, to a panel of the type comprising at least a substrate and an upper layer provided on the substrate, wherein the upper layer is on a printed pattern directly on the substrate and on the printed pattern. A transparent or translucent synthetic material layer provided, wherein the transparent or translucent synthetic material layer comprises vinyl and the primer is provided between the printed pattern and the vinyl containing synthetic material layer. Preferably, the translucent synthetic material layer consists essentially of vinyl and / or plasticizer. Since vinyl is applied to the surface, a pleasant feeling is created on the surface of the panel. The primer allows for economically obtaining adhesion of the vinyl-containing synthetic material layer to the base layer, for example a printed patterned ink. The inventors have found that such attachment can be achieved in UV based inks as well as in aqueous inks. Preferably, there is no additional material and / or layer between the printed patterned ink and the vinyl containing synthetic material layer.

Preferably, the vinyl containing synthetic material layer has a thickness of at least 0.2 millimeters or more. The inventors have found that even when the panel of the present invention is to be applied as a floor panel, this thickness of the composite material layer already allows to obtain acceptable wear resistance. In addition, this layer has good transparency. Because of this layer of vinyl-containing synthetic material, the use of wear resistant particles, such as aluminum oxide particles, which are usually applied to floor panels, can be omitted in this layer. Such wear resistant particles have a negative effect on the transparency of the synthetic material layer, and limiting the amount of such particles leads to a better rendition of the printed pattern. Preferably, where wear resistant particles are applied, less than 10 g / m 2 or more preferably 5 g / m 2 of such particles are applied. Of course, this invention does not exclude that larger amounts of such particles are applied to the vinyl containing synthetic material layer.

Preferably, the thickness of the vinyl containing synthetic material layer is less than 1 millimeter. This thickness leads to a high wear resistant surface layer, which will be sufficient in most cases and is still sufficiently transparent.

A very interesting value for the thickness of the vinyl containing top layer that provides an optimal value between cost and wear resistance is in the range of 0.25 to 0.5 millimeters. Because of this thickness, no additional wear resistant particles are needed.

It is noted that, according to the present invention, still one or more additional layers may be provided over the vinyl containing synthetic material layer. The common thickness of this additional layer is preferably smaller than the thickness of the vinyl containing synthetic material layer, more preferably at least 5 times smaller. The additional layer may, for example, comprise a UV cured layer, which may increase the resistance so that black stripes do not occur, for example, rubbed off by shoe soles. It is not excluded that the one or more additional layers include abrasion resistant particles that increase scratch resistance. Here, this may relate to, for example, aluminum oxide or silicon oxide particles having an average diameter of less than 60 micrometers, more preferably less than 10 micrometers. This additional layer also does not exclude the absence of such wear resistant particles or the inclusion of at least less than 10 g / m 2 or less than 5 g / m 2 of such particles.

Preferably, primers comprising or substantially based on polymers having aliphatic properties are applied. The inventors have discovered that polymers having aliphatic properties tend to be less yellowing compared to polymers having aromatic properties, thus ensuring better transparency of the vinyl-containing synthetic material layer. Of course, it does not exclude that primers based on aromatic polymers may still be used within the spirit of the invention. In this case, preferably also UV blockers and / or whiteners are applied to the primer and / or layers of vinyl-containing synthetic material located thereon. As the bleach, for example, a substance comprising a derivative of the distyryl biphenyl compound can be applied.

Preferably, the primer comprises polyurethane and / or polyisocyanurate, or the primer is based on one or both of these polymers. As mentioned above, this preferably relates to aliphatic variants of these agents. The inventors have found that polyurethanes or polyisocyanurates realize good adhesion between the vinyl-containing synthetic material layer and the printed patterned ink in an economical manner. This may, for example, relate to UV based inks or aqueous inks.

Preferably, the transparent or translucent synthetic material layer is free of paper sheets or sheet of material such as synthetic material sheets or films. Such sheets have a negative effect on the transparency of each layer; Besides, it requires extra cost.

As mentioned above, the transparent or translucent synthetic material layer is preferably free of additives which increase the wear resistance of the panel, or at least it comprises less than 10 g / m 2 of such additives.

Said vinyl at least partially forming a transparent or translucent synthetic material layer is preferably substantially related to polyvinyl dichloride (PVdC). In general, PVdC is more expensive than PVC (polyvinyl chloride), but has lower water permeability. Waterproof is a desired property for many decorative surfaces such as floor panels or furniture panels. The present invention does not exclude that vinyl can be used that is substantially related to polyvinyl chloride.

According to a variant, said vinyl is at least partly, preferably substantially or wholly related to a chlorine-free vinyl compound, preferably selected from the list of vinyl acetates such as polyvinyl butyrate, polyvinyl alcohol and EVA (ethylene vinyl acetate). You will get a more environmentally friendly panel.

Preferably, the vinyl-containing synthetic material layer, and more preferably the entire top layer, is free of plasticizer or contains up to 35 parts by weight of plasticizer, or more preferably less than 20 parts by weight of plasticizer per 100 parts by weight of vinyl compound. Restricting the plasticizer content results in a stronger surface with better impact resistance. In addition, since the risk of generating harmful substances, for example steam, is limited in this way, it is of interest to greatly omit plasticizers when producing such panels. When the plasticizer is applied, a phthalate based plasticizer such as, for example, DINP (diisononyl phthalate) may be selected. Preferably, in this case, however, plasticizers based on isosorbide are employed. The last mentioned plasticizer is more environmentally friendly.

According to a deviating variant, the synthetic material layer comprises polyurethane instead of vinyl, which polyurethane is preferably aliphatic, and preferably relates to a so-called polyester based thermoplastic polyurethane. The inventors have found that the use of this layer of synthetic material allows to achieve good scratch resistance at the surface of the panel. In addition, polyurethane shows better resistance to fouling by freshness than vinyl. Thus, additional UV based surface layers to limit or offset this phenomenon are unnecessary in the case of polyurethane containing surface layers. Preferably, the polyurethane composite material layer thus forms a transparent or translucent layer present on the actual surface of the panel. Preferably, the thermoplastic polyurethane layer or film has a thickness between 0.1 and 0.3 mm, or a plurality of such layers or films have a common thickness between 0.1 and 0.3 mm. This thickness is sufficient to achieve acceptable wear resistance for the floor panels. Of course, thicker layers are still not ruled out as they can result in higher wear resistance. The inventors have found that a thickness of 0.15 mm allows to obtain a Taber IP value (EN 13329) of at least 3,000. This value can even be achieved when the synthetic material layer does not have additional wear resistant particles. When aromatic polyurethanes are applied, UV blockers or bleaches, such as substances comprising derivatives of distyryl biphenyl compounds, are also preferably used. The inventors have found that no additional measures need to be taken to separate the press platen and the composite material layer, for example, with a metal press platen to perform the press treatment on the polyurethane containing synthetic material layer. Also found. It is clear that the remaining preferred embodiments of the first aspect of the present invention can be applied in combination with a polyurethane-containing synthetic material layer with only minor modifications of the necessary parts.

The above modified variant is generally regarded as a particular independent aspect of the present invention, which can also be defined as a panel of the type comprising at least a substrate and an upper layer provided on the substrate, the upper layer being a printed pattern and the printed pattern. Note that it comprises a transparent or translucent synthetic material layer provided over the pattern, wherein the transparent or translucent synthetic material layer comprises polyurethane. As in the first aspect, it is clear that the printed pattern herein can be formed directly on the substrate or provided on a carrier material such as a paper sheet or a composite material film, preferably a polyurethane film. In addition, according to this particular independent embodiment, it is clear that the primer does not necessarily need to be used.

Preferably, the pattern is provided directly to the substrate via one or more primer layers. The use of the primer layer is thus known from the patent literature mentioned in the introduction. Preferably, the primer layer is based on a synthetic resin such as UV lacquer, melamine formaldehyde resin and / or vinyl. In the last case, the above-mentioned vinyl compound can be applied whether or not it is chlorine free. Preferably, by the primer layer, a printing background of uniform or substantially uniform color is obtained.

Preferably, the pattern is printed by UV based ink. Such inks have good UV stability. In addition, the primer and vinyl containing synthetic material layers allow for such UV ink application.

According to a first aspect of the invention, the vinyl-containing synthetic material layer is preferably provided to the panel as a material such as liquid or paste, which is applied after it has been applied, for example by means of an oven, press or lamp, for example an infrared lamp. Dried or cured. For drying or curing, heat of the heated element can also be used, which is then supplied directly or indirectly to the liquid material. For example, for this purpose the panel can be carried over one or more heated rollers. Preferably, the material such as a liquid or paste relates to a so-called plastisol comprising at least a vinyl compound suspended in a plasticizer, preferably PVC. Plasticizers can form, for example, at least 50% by weight of suspensions or pastes associated with phthalate compounds such as diisononyl phthalate (DINP).

Applying a material such as, for example, a liquid or paste, can be performed, for example, by providing the material directly to the printed substrate by means of a spreading device. According to another possibility of this, a liquid material or paste is first provided to the carrier material and then transferred to the printed substrate, which carrier material may or may not be moved together. When the carrier material is carried together on the substrate and held there in the final panel, where it is not needed, it is preferably related to the carrier material which becomes transparent or translucent or becomes transparent or translucent. For example, transparent or translucent synthetic material films based on vinyl compounds such as PVC can be used, for example.

As an alternative, the vinyl containing layer or part thereof may also be applied as one or more vinyl containing synthetic material films. In addition, according to the modification variant described above, polyurethane or part thereof may also be provided to the substrate as one or more films. It is clear that this alternative and this modified variant can be combined with a part of the synthetic material layer applied in liquid form.

According to a preferred embodiment of the invention, the panel of the invention comprises an embossment on its surface, which embossment extends from the layer of vinyl containing synthetic material; However, preferably the embossed recess is only too deep so that the recess does not penetrate the printed pattern. To provide this relief, any technique may be used. Preferably, a technique is used in which the structure of the structured press element is copied to the surface of the layer of vinyl containing synthetic material, for example by press treatment. Preferably, the composite material layer is heated before and / or during the press treatment. By heating the synthetic material layer, the synthetic material layer is preferably softer, whereby the press treatment can be realized at a lower pressure. In the case of the preceding heating, a radiation source such as an infrared radiator is preferably used. If heating is carried out during the press treatment, then heating is preferably carried out by means of a thermal oil in which the press machine and the press element are warmed up. Preferably, the composite material layer is forcedly cooled during and / or after pressing. By cooling, the structure at the surface of the synthetic material layer will be better preserved. Preferably, a temperature of at least 130 ° C. is achieved during the press treatment. For this cooling, the same press treatment can be used, or a separate treatment and press machine can be used which is preferably not heated or even cooled afterwards. It is also possible that the above-described structured press element is applied only during this cooling and / or in this case only the adhesion between the other layers of the panel during the first press treatment. Said cooling means that the consolidated panel is still warm from the first press treatment and / or reheated before it is subjected to the second press treatment.

Preferably, an opening and closing discontinuous press or a so-called short-cycle press is applied, and one package of substrate, printed pattern and composite material layer is pressed every cycle. It is also possible to work with so-called multiple-opening presses, whereby a plurality of packages can be pressed per cycle.

According to a second independent aspect, the invention relates to a panel of a type comprising at least a substrate and a top layer provided on the substrate, the top layer comprising a layer of vinyl based synthetic material, the substrate preferably comprising wood or wood And a primer is provided between the substrate and the vinyl based synthetic material layer. Preferably, no further material or layer is present between the substrate and the primer and / or between the primer and the vinyl based synthetic material layer.

Preferably, polyurethane-containing materials such as polyurethane-based dispersion adhesives are applied as primers. Preferably, this primer is provided for binding between the layer of synthetic material and the substrate, more preferably no further binding agent is provided for this purpose.

Preferably, the vinyl based synthetic material layer relates to a vinyl film, for example a PVC film. Here, this may relate to a decorative film showing a printed pattern. It may also relate to transparent films or possibly colored films. Preferably, the layer of vinyl based synthetic material relates to at least a decorative film printed by solvent ink. With solvent inks, very high printing quality can be achieved. According to a modification variant of the second aspect, a polyurethane-containing synthetic material layer, such as a thermoplastic polyurethane film, is used. For this purpose, the material mentioned in the modification specific embodiment of the first aspect is preferably applied. Of course, the preferred embodiment of the second aspect can also be carried out by such a polyurethane-containing synthetic material layer instead of a vinyl-containing synthetic material layer.

According to a particular embodiment, the vinyl based synthetic material layer comprises a transparent or translucent vinyl based film as a vinyl based decorative film, wherein the transparent or translucent vinyl based film is provided over the decorative film.

According to another particular embodiment, the vinyl-based synthetic material layer comprises a vinyl-based decorative film, as well as a transparent or translucent vinyl-based layer free of films and other sheets. This transparent or translucent layer can be obtained as described by the first aspect of the invention, for example by applying the liquid substance or paste mentioned in the first aspect.

According to this second independent aspect it is also clear that the surface of the panel, more particularly the vinyl based synthetic material layer, may be embossed in any manner. Preferably, one or more possibilities for it described in the first aspect can be applied for this purpose.

According to a third independent aspect, the invention relates to a method for manufacturing a panel, wherein the panel is of a type comprising at least a substrate and an upper layer provided on the substrate, the method comprising at least the following steps:

Preparing a substrate;

Performing a print on the substrate;

Providing a primer to the print; And

Providing a vinyl- or polyurethane-containing material to the substrate.

The vinyl- or polyurethane-containing material provided in the substrate according to the third aspect can be located anywhere in the final top layer of the panel. For example, this may form part of a layer that serves as a primer layer for the print, and / or form part of a layer of transparent or translucent synthetic material located over the print. Preferably, the vinyl- or polyurethane-containing material is located at least in the transparent or translucent synthetic material layer and the primer realizes at least partially bonding between the print and this transparent or translucent synthetic material layer.

Preparing the substrate may, for example, involve grinding and / or providing one or more primer layers. The primer layer is preferably made of lacquer or synthetic resin, whereby at least a uniform printing background is realized. The primer layer is preferably applied in a liquid or viscous form, for example paste, and dried. For this purpose, preferably one or more roller machines, respectively ovens or other heating appliances are applied.

As mentioned above, the primer layer may also comprise a vinyl containing material and may substantially consist of, for example, a possible example for the material of the vinyl containing synthetic material layer mentioned in the first aspect, whereby the primer layer necessarily It does not need to be a transparent or translucent layer, but preferably results in a uniform, eg white or beige printing background.

As the primer, preferably any primer described by the first aspect is applied. For the vinyl containing material, the material designated as a possible example for the transparent or translucent synthetic material layer in the first aspect is preferably applied.

The print forming step is preferably performed by a digital printing device, for example by an inkjet printer. Here, UV-based inks are preferably applied. Of course, aqueous ink or solvent ink is not excluded.

The method of the third aspect is in particular adapted to produce a panel of the first aspect or a modified variant thereof or of a particular aspect of the first aspect, wherein the preferred embodiment of this aspect or variant is a corresponding preferred embodiment of the third aspect. It is clear to elicit form.

According to a fourth independent aspect, the present invention also relates to a method for manufacturing a panel, wherein the panel is of a type comprising at least a substrate and a top layer provided on the substrate, the top layer comprising at least a synthetic material film, the method being increased And providing said film to the substrate by press treatment at a predetermined temperature. The purpose of the press treatment can be twofold. That is, this purpose may include applying a film to the substrate and providing a structure to the surface of the top layer.

Preferably, the method of the fourth aspect further comprises at least providing a primer to a substrate, preferably a polyurethane dispersion adhesive.

The method of the fourth aspect is particularly adapted to produce the panel of the second aspect, and it is evident that the preferred embodiment of the second aspect leads to the corresponding preferred embodiment of the fourth aspect.

As the synthetic material film, preferably a PVC film or a thermoplastic polyurethane film is used. The film can be printed to form a possible printed pattern of the panel, or can be made transparent or translucent and in this way can form a protective layer over this possible pattern. In the case of polyurethanes, aliphatic or aromatic variants are preferably used, where the aromatic variants preferably contain UV blockers and / or bleaches. As examples of bleach, reference is made to the foregoing embodiments and variants, wherein each of the materials mentioned therein can be used for application to this fourth embodiment.

Preferably, the substrate is associated with a wood containing or wood based substrate such as MDF or HDF or wood particle board. According to a variant, the substrate comprises a foamed synthetic material such as foamed polyethylene or foamed polyvinyl chloride.

In general, the substrate is preferably related to the porous substrate, as is the case described above. By such a substrate, good peeling resistance or in other words, separation resistance of the upper layer can be achieved. In principle, this is sufficient when the surface of the substrate with the top layer is porous. However, making the entire substrate porous is not excluded.

Preferably, the top layer comprises at least two synthetic material films, for example decorative films and transparent films. If possible, this may refer to the hermetic film here. In that case, it is preferably taken to prevent the inclusion of air between both synthetic material films. For example, one or both of the composite material films may be made to be perforated so that accumulated air may leak along this perforation if possible.

Preferably, the method of the fourth aspect comprises a step performed before the press treatment step, in which the two synthetic material films are laminated to a combined film. In this way, the logistics of the method are simplified. In the case of hermetic films, in this way any air inclusions are avoided before the press treatment. Preferably, laminating is performed by a calendering machine or another machine to which a roller is applied. By the roller, air can be gradually discharged from between the composite material film.

According to a particular embodiment, the top layer comprises at least paper sheets with a thermoplastic synthetic material such as PVC, polyisocyanate or polyurethane prior to the press treatment, and at least a synthetic material film such as a thermoplastic polyurethane film or a PVC film, and then at least The board | substrate, the said paper sheet, and the said composite material sheet are mutually bonded by the press process of a 4th aspect. Preferably, the paper sheet relates to a printed paper sheet, and the print provides a printed pattern in the top layer of the panel. In this case, the synthetic material film preferably forms a protective layer over the printed pattern. The paper sheet and the composite material film are preferably attached to each other in separate processing steps by a calendering machine or another machine to which a roller is applied. This separate treatment step is preferably performed before the press treatment.

Preferably, the press treatment is carried out at a temperature between 80 ° C and 150 ° C, or more preferably between 110 ° C and 140 ° C. This temperature is sufficient to achieve adhesion of the synthetic material film onto the substrate and the primer. Preferably, an open / close discontinuous press or a so-called short cycle press is applied, one cycle of the substrate and one package of one or more composite material films each pressed every cycle. It is also possible to work with a so-called multistage open press, in which a plurality of packages can be pressed per cycle.

Preferably, the press treatment is carried out with a pressing time shorter than one minute. The inventors have found that this pressing time is sufficient to achieve good adhesion. At the same time, it is possible to provide the structure to the surface of the panel, in particular the composite material film, by press treatment. According to a preferred embodiment, this starts with at least one flat, unstructured synthetic material film, preferably a transparent or translucent synthetic material film, which is attached to the substrate in the press treatment and also has a structure. In order to realize the structure, a structured press element, for example a structured press platen or press plate, is preferably used during the press treatment. Preferably, the structure is carried out in accordance with the printed pattern, for example, the pattern of the decorative film. Preferably, the structure is obtained by a press treatment carried out in an open / close press. Preferably, the press element has a coating that facilitates separation of the press element from the panel.

For the quality of the structure obtained, it may be desirable for the package to be cooled under pressure. For this purpose, the same press treatment in which the top layer is attached to the substrate can be used, or a separate press machine can be used which is preferably not preferably heated or possibly even cooled afterwards. It is also possible that the above-mentioned structured press element is applied only during this cooling, and / or in this case only adhesion between the other layers of the package is obtained during the first press treatment. Said cooling means that the integrated package is still heated again before receiving a warm and / or second press treatment from the first press treatment.

This last possible example forms the application of the broader inventive concept of the invention, which will be described below as the second specific independent aspect.

According to this second particular, independent aspect, the invention relates to a particular combination of the foregoing possibles of the fourth aspect, in which all the essential parts of the method of the fourth aspect need not necessarily be applied. To this end, the invention relates to a method for manufacturing a panel, the panel is of a type comprising at least a substrate and an upper layer provided on the substrate, the upper layer comprising a thermoplastic synthetic material, wherein the method comprises the first thermoplastic composite material. At least a first step subjected to a temperature and a first pressure, wherein the structure is formed from the thermoplastic synthetic material and the thermoplastic synthetic material comprises at least a second step subjected to a second temperature and a second pressure, the first The temperature is higher than the second temperature and the second pressure is preferably higher than the first pressure.

The inventors have found that, after the thermoplastic synthetic material has been subjected to heat treatment at lower pressure, forming the structure at lower temperatures leads to better rendering and maintenance of the provided structure.

For fringes, printed synthetic material films such as printed vinyl based films, or printed polypropylene films, or printed polyethylene films, or printed polyurethane films are preferably used. The print is preferably located on the top side of this film, but it is not excluded that it may be provided at least partially on the bottom side of the film, so that the actual film is made transparent or translucent and, if possible, the thermoplastic synthetic material or its To form part. Preferably, the connection between the printed synthetic material film and the substrate is achieved at least via the adhesive layer, preferably via the polyurethane dispersion adhesive. According to an alternative, for the pattern, a pattern printed directly on the substrate is used, similar to the direct printed pattern described in connection with the first aspect; That is, similar inks and / or similar primer layers can be applied.

Preferably, when performing the second step, the thermoplastic composite material forms the surface of the integrated package comprising at least the substrate, the pattern and the thermoplastic composite material. According to an alternative, at this stage of the process the thermoplastic synthetic material is further finished with one or more layers provided thereon, including for example a UV-cured or cured layer. For this purpose, the material of the UV-cured or cured layer mentioned in connection with the first embodiment can be applied, regardless of the amount mentioned therein and / or the wear resistant particles mentioned therein. In any case, the thermoplastic synthetic material preferably relates to a transparent or translucent thermoplastic synthetic material layer applied on the pattern in any manner as a synthetic material film or liquid material or paste. As the material for the thermoplastic synthetic material, a vinyl based synthetic material such as PVC, or polypropylene, polyurethane or polyethylene can be adopted.

If a film is used for the pattern as well as the transparent or translucent layer, this may include, for example, at least a laminated film and, for example, to form a bonding film or an integrated package that also includes the substrate, Preferably they are laminated to each other at least before the second step. Laminating may be performed by a calendar device, for example, as described in connection with the fourth aspect of the present invention.

Preferably, an integrated package is formed before and / or in conjunction with the first step, the package comprising at least the pattern and the thermoplastic composite material. Preferably, such an integrated package can be used at least before the second step. If possible, this integrated package may also include a substrate and / or a thermoplastic backing layer on the underside of the patterned or printed composite material film. It is possible here to apply a method having the features of the fourth aspect. According to another possibility, a calender or continuous press machine is applied to join two or more layers of the integrated package together. According to another possibility, for example, at least the thermoplastic synthetic material is realized by applying a liquid substance or paste to the substrate and / or the pattern. In this last case, the thermoplastic synthetic material can be performed without a film or other sheet. To this end, a method similar to the method described in connection with the third and / or fifth aspect can be applied, so that instead of the pattern printed directly on the substrate, it is also possible to bond it to the substrate or possible back layer in the manner described above. Printed synthetic material films are used. Preferably, the attachment between the pattern and the thermoplastic top layer is obtained by the material of this pattern, or possibly by the printed synthetic material film and the thermoplastic layer itself, thus without using an outer adhesive layer.

If not necessarily the case, if the top layer comprises a back layer, a back layer is preferably used, preferably made of PVC or other thermoplastic synthetic material, preferably recycled PVC, preferably filled with chalk. This backing layer preferably forms at least 30%, and more preferably at least 45% of the top layer thickness.

As mentioned above, the aforementioned first temperature and first pressure to which the thermoplastic composite material is imparted can be generated, for example, by forming an integrated package of at least a pattern and a thermoplastic composite material by a calender or continuous press machine. . According to another possibility, it is generated by a radiation source, preferably a heating device such as an infrared lamp. In this last case, it is clear that the first pressure may be equal to atmospheric pressure. The first temperature is preferably higher than room temperature (23 ° C.) and is at least 50 percent, more preferably higher than 80 percent, of the glass transition temperature (Tg) of each thermoplastic composite material, expressed, for example, in degrees Celsius. . Of course, the first temperature may also be higher than the glass transition temperature, and preferably, however, it may be higher than 150 percent of the glass transition temperature. In this proposed range of first temperatures, an ideal suitable ductility of the thermoplastic synthetic material is achieved in order to proceed to the second step. Preferably, the second step is performed without forcibly cooling the thermoplastic composite material and / or without applying a stop period therebetween. Preferably, at the beginning of the second stage, the thermoplastic composite material has at least 80 percent of the temperature that the composite material has at the end of the first stage, and anyway at least above room temperature.

The second temperature and the second pressure imparted to the thermoplastic synthetic material may be generated by a press treatment using a structured press element, similar to the press treatment described in connection with the first or fourth aspect of the invention. . Preferably, however, open and close discontinuous press machines or so-called short cycle presses are applied, which include structured press plates or press platens. Preferably, in the second step cooling is achieved under pressure of the thermoplastic upper layer, while at the same time embossing is realized on the surface of the thermoplastic synthetic material and / or the integrated package. Preferably, the press device comprising the press platen is maintained at a temperature lower than the temperature of the thermoplastic synthetic material at the beginning of the second step. Preferably, in a press machine comprising a press platen, no heat is supplied except for the possible heat of the thermoplastic synthetic material itself. The second temperature is preferably between 20 and 55 ° C. or less than 50 percent of the glass transition temperature of each thermoplastic composite material. The second pressure is preferably between 1 and 10 bar. The inventors have found that short pressing times, for example pressing times of less than 1 minute, such as between 5 and 50 seconds or even between 5 and 25 seconds, can be handled. Preferably, the structure is obtained according to the pattern.

Preferably, in the second stage, compared to the first stage, a separate device is applied.

According to a first important embodiment of the second specific aspect, a combination comprising, before the first step, an MDF substrate, a backing layer provided on the upper side of the substrate and a backing layer or base layer provided on the lower side of the substrate composition is formed. This combination is obtained by adhering the base layer and the backing layer to the substrate with a polyurethane based adhesive such as a polyurethane dispersion adhesive. Thereafter, a transparent or translucent thermoplastic film such as a printed synthetic material film and a PVC film is placed on the side of the binder, more particularly the binder comprising the back layer. This package is integrated in the first stage by a hot press machine, for example a continuous work press machine. During this press treatment, the first temperature and the first pressure are achieved. Herein, integration occurs because the initial bond and the composite material film melt together in positions adjacent to each other. In the second stage, the still warm integrated package is fed to an unheated short cycle press comprising a structured press element. After a 15 second pressing time, a structured panel is obtained. Since the short cycle press is in the unheated state, the second temperature can be kept below the first temperature in a simple manner. However, preferably the second pressure is higher than the first pressure.

According to a second important embodiment of the second particular aspect, before the first step, a combination is formed comprising an MDF substrate, a reinforcing layer or base layer provided on the underside of the substrate. This combination is obtained by providing a base layer to a substrate as a liquid or paste-like material and curing or drying the base layer there. On top side of the substrate is sprayed an adhesive, such as a polyurethane based adhesive, for example a polyurethane dispersion adhesive. Thereafter, transparent or translucent thermoplastic films such as printed synthetic material films and PVC films are placed on the side of the binder, more particularly the binder comprising the adhesive. In a first step, the package is integrated by a hot press machine, for example a continuous work press machine. During this press treatment, the first temperature and the first pressure are achieved. Here, integration occurs because the initial bond and the composite material film are glued to each other and at the same time the composite material film melts together with each other at locations adjacent to each other. In the second stage, the still warm integrated package is fed to an unheated short cycle press comprising a structured press element. After a 15 second pressing time, a structured panel is obtained. Since the short cycle press is in the unheated state, the second temperature can be kept below the first temperature in a simple manner. However, preferably the second pressure is higher than the first pressure.

According to a third important embodiment of the second particular aspect, before the first step, a combination is formed comprising an MDF substrate, a reinforcing layer or base layer provided on the underside of the substrate. This combination is obtained by providing a base layer to a substrate as a liquid or paste-like material and curing or drying the base layer there. On top side of the substrate is sprayed an adhesive, such as a polyurethane based adhesive, for example a polyurethane dispersion adhesive. Prior to the first step, the bonding film is also formed on the basis of the printed synthetic material film and the thermoplastic synthetic material, for example also in the form of a film. This bonding can be done by laminating both, or by providing the thermoplastic synthetic material in the form of a liquid or paste to the printed synthetic material. Thereafter, the bonding film is arranged on the substrate side, more particularly on the substrate side comprising the adhesive. This package is integrated by the reaction of the adhesive. In a first step, the integrated package is heated by an infrared radiation device. During this heating step, the first temperature and the first pressure are achieved. In this case, the first pressure is equal to atmospheric pressure. In the second stage, the still warm integrated package is fed to an unheated short cycle press comprising a structured press element. After a pressing time of 15 seconds, a structured panel is obtained. Since the short cycle press is in the unheated state, the second temperature can be kept below the first temperature in a simple manner. In this case, however, preferably the second pressure is clearly higher than atmospheric pressure.

Before obtaining the final floor panels, it is clear that the panels of the first to third embodiments may be subjected to further treatment. For example, the panel may also be divided into a plurality of smaller panels approximately having the dimensions of the final floor panel.

It is noted that by the second particular aspect a very good agreement between the structure and the pattern can be obtained. Substantially in the background of applying a continuous press machine and / or a multistage open press, this agreement is not achieved so far. Preferably, the structure is realized entirely by the second step, and thus, at the beginning of the second step, the thermoplastic synthetic material is still embossed or free of any structure.

It is clear that the second specific aspect can be applied, for example, to produce a panel having the features of the first or second aspect of the invention.

According to a fifth independent aspect, the invention also relates to a method of manufacturing a panel, wherein the panel is of a type comprising at least a substrate and an upper layer provided on the substrate, the upper layer being at least a printed pattern and a transparent provided on the pattern or A layer of translucent synthetic material, the method provides a vinyl containing paste over a printed pattern to form at least a portion of the layer of transparent or translucent synthetic material and, by press treatment, embosses the layer of transparent or translucent synthetic material. It provides at least a step of providing. Preferably, the pastes applied herein relate to suspensions of PVC in so-called plastisols or plasticizers. For this purpose, it is clear that the pastes mentioned in other embodiments can be applied.

According to a preferred embodiment, the paste is provided on the synthetic material film or the synthetic material layer with the printed pattern. Preferably, this relates to printed PVC or polyurethane films. In the case of polyurethane films this preferably relates to thermoplastic polyurethane films of the aliphatic type or of the aromatic type, and in this last case preferably also the UV blocker and / or plasticizer is the upper layer, preferably at least this UV blocker or bleach Applies to places within and / or above As examples of thermoplastic polyurethane films and bleaches, other embodiments are referenced. Printing is preferably performed by solvent ink. According to another possibility, UV based inks may be applied.

According to a first specific embodiment of the above preferred embodiment, the composite material layer provided with the paste according to the fifth aspect comprises at least a back layer and a composite material film, the printed pattern is provided on the composite material film, and The back layer and the printed synthetic material film are preferably provided superimposed on each other prior to the step of providing the paste. The back layer preferably consists of PVC, preferably recycled PVC, and is preferably filled with chalk. This back layer forms preferably at least 30%, more preferably at least 45% of the top layer thickness. Preferably, the layer obtained by the paste forms at least 10 percent, more preferably at least 15 percent of the top layer thickness. The preferred thickness of this layer is at least 0.2 millimeters. Preferably, the thickness of this layer is less than 0.5 millimeters.

According to another second specific embodiment of the above preferred embodiment, which may be combined with the first specific embodiment if possible, the composite material film to which the paste is applied is in the shape of a web. The application of the paste is then preferably carried out continuously, while, for example, the synthetic material film is fed in a roll. In this case, the press treatment can be carried out by a continuous press machine if possible. Preferably, the web with paste, however, is divided into sheets, which are then subjected to press treatment in this form. In this last case then preferably the above-mentioned opening and closing press machine is also used.

The total thickness of the top layer is preferably between 1 and 3 millimeters, more preferably between 1.5 and 2.5 millimeters.

The layer realized by the paste is preferably free of wear resistant particles such as aluminum oxide. Nevertheless, when such particles are present, the particles preferably have a concentration of less than 10 g / m 2, more preferably less than 5 g / m 2.

Preferably, after the paste is provided on the printed pattern, an upper layer or an upper layer portion comprising the printed pattern is provided on the substrate. This results in a smoother process. After the composite material film having the substrate and the paste has already been joined together, the press treatment of the fifth aspect for forming the relief is preferably performed. Preferably, the top layer is attached to the substrate by a press process, which coincides or does not coincide with the press process for embossing. According to an alternative, a press treatment of the fifth aspect is performed in which the composite material film with the substrate and the paste is embossed before they are joined together or in any way at least before they are attached to each other. In this last case, attachment can be achieved by press treatment and / or by adhesive connection. Preferably, however, adhesion is used, with the material of the top layer and the substrate itself, thus not using an outer adhesive layer.

Preferably, the paste is at least partially cured or gelled before the press treatment. It is clear that this curing takes place while the paste is already provided in the pattern.

Preferably, the press treatment also supplies heat to the transparent or translucent layer, which layer if possible comprises a paste which has not yet cured. Thus, the curing or gelling step can be at least partially achieved by the press treatment of the fifth aspect, if possible. When the paste has at least partially or even fully gelled before the start of the press treatment, it is possible for the curing to be reversed at least partially again by the heat of the press treatment, that is to say that the transparent or translucent synthetic material film is softened again.

Preferably, the transparent or translucent layer is formed substantially by the paste. If possible, also on the surface of the panel, one or more additional layers, for example a UV cured layer, of a type similar to that described by the first aspect can be applied.

According to a sixth aspect, the invention also relates to a panel of a type comprising at least a substrate and an upper layer provided on the substrate, wherein the upper layer comprises a printed pattern, a sheet of paper and a layer of transparent or translucent synthetic material, said The paper sheet is characterized by having a thermoplastic synthetic material and wherein said transparent or translucent synthetic material layer comprises a thermoplastic synthetic material. It is evident that the layer of transparent or translucent synthetic material is preferably placed over a printed pattern here. First of all, reference is also made to the above-mentioned specific embodiment of the fourth aspect, which shows an embodiment of the invention according to this sixth aspect.

Synthetic materials applied to paper sheets are preferably related to polyurethanes or polyisocyanates. Preferably, the synthetic material is provided by soaking the paper sheet into such a synthetic material or otherwise impregnating the paper sheet with the synthetic material. Paper sheets with thermoplastic synthetic materials according to the invention are preferably related to printed paper sheets, which paper sheets exhibit the printed pattern. According to an alternative, the paper sheet may also be a transparent paper sheet provided on the printed pattern as a protective layer. In such a case, the printed pattern may be provided in a separate sheet of material, or printed directly on the substrate whether or not via a primer layer.

The synthetic material of said transparent or translucent synthetic material layer is preferably related to a vinyl compound or polyurethane. Preferably, for example, thermoplastic polyurethane films of the type also mentioned in the preceding embodiments are applied.

Preferably, the paper sheet with the synthetic material and the transparent or translucent synthetic material layer are provided to the substrate by a calendering machine.

According to a seventh aspect, the invention also relates to a panel of a type comprising at least a substrate and a top layer provided on the substrate, the top layer comprising a printed pattern and a layer of transparent or translucent synthetic material provided on the printed pattern. Wherein the top layer is comprised of at least one layer comprising a thermosetting synthetic resin and at least one layer comprising a thermoplastic synthetic resin. As the thermosetting synthetic resin, a polycondensation resin such as melamine resin can be used. As the thermoplastic synthetic resin, a vinyl compound or polyurethane can be used.

Preferably, the layer related to the thermosetting resin is related to the decorative paper provided with such a resin. Here, the decorative paper thus comprises at least part of the printed pattern. Preferably, the layer with the thermosetting resin is located in direct contact with the substrate. By this thermosetting resin, bonding with the substrate may be achieved, ie preferably without external adhesive connection.

Preferably, the layer comprising the thermoplastic synthetic material relates to at least a transparent or translucent layer applied over the printed pattern and preferably above the layer with the thermosetting resin. In this way, a surface layer having specific properties can be obtained. When the layer with the thermoplastic synthetic material has a thickness that is between 0.1 millimeters and 0.5 millimeters, acceptable wear resistance can be obtained for floor coverings or floor panels, even without the use of additional wear resistant particles. For good quality, a thickness of 0.25 to 0.4 is preferred. Of course, it does not exclude that this layer should be made thicker than 0.5 millimeters.

According to a first possibility, the layer comprising the thermoplastic synthetic material can be at least partly applied as a material such as a liquid or a paste. For this purpose, reference is made to embodiments of other aspects. According to a second possibility, the layer comprising the thermoplastic synthetic material can in turn be partially provided as a material sheet with such a synthetic material, for example a paper sheet. For this purpose, reference is made to embodiments of other aspects, in particular of the sixth aspect. According to a third possibility, the layer comprising the thermoplastic synthetic material can be at least partially provided as a synthetic material film, for example a PVC film or a polyurethane film. For this purpose, reference is made to embodiments of such films of another aspect.

In all embodiments, a porous substrate, such as a wood based substrate, is preferably applied. The substrate may be associated with, for example, MDF or HDF (medium density fiberboard or high density fiberboard) or wood particle board. Another possible substrate is a substrate comprising foamed material, such as a substrate comprising foamed polyethylene or polyvinyl chloride. Preferably, the substrate has a density of less than 800 kg / m 3, more preferably 500 kg / m 3, the lowest density being preferably achieved by the substrate containing foam material.

In all aspects, the present invention relates to a flooring panel or other panel that is thus rigid and cannot be wound like this. Preferably, the final panel has a thickness of more than 5 millimeters, but preferably less than 15 millimeters. Good values for the thickness are 7 to 10 millimeters. Such panels are well suited to provide thereon mechanical coupling means thereon that allow to join two or more such panels together at their edges. Preferably, mechanical coupling means, such as the type known in WO 97/47834, are used.

According to all aspects and variants, when a calendering or calendering machine is mentioned, it is meant a device in which the two layers are attached to each other by at least a roller, preferably by supplying heat.

According to all aspects and variants, when a synthetic material film is mentioned, it is evident that this film consists essentially of the synthetic material so that there are no other materials such as paper.

In addition, when mention is made of curing or gelling of a liquid substance or paste, it is evident that at least an increase in the viscosity of such substance or paste appears. In the case of vinyl- or PVC-containing pastes, preferably at least 5 to 75% by weight of plasticizers are used in addition to the PVC powder and after curing, so-called soft PVC is obtained. Preferably, in addition to PVC powders and plasticizers, such PVC pastes also contain 3-15% by weight of waxes such as polyethylene wax or montan ester wax. The curing or gelling step can be carried out in several substeps, for example, the heat is supplied to the paste each time by a heated element in direct or indirect contact with the paste or by means of an infrared lamp. Preferably, the temperature applied to the surface of the paste is here between 40 ° C and 200 ° C, more preferably between 110 ° C and 175 ° C.

It is also possible to start with the manufacture of larger boards, if possible, in the method of the invention, whereby a plurality of panels, such as floor panels, can be obtained by subsequently subdividing from the larger boards, for example by sawing. Note also that. This dividing step can occur at any time, and it is not necessary for all essential steps of each independent aspect of the present invention to have already been completed before such a subdivision. In other words, one or more of the steps may be performed in a smaller panel.

It is also noted that the features of the above aspects can be combined as long as they do not contradict each other.

The invention is in no way limited to the embodiments described above herein, on the contrary, such methods and panels may be realized in accordance with various modifications without departing from the scope of the invention.

Claims (32)

A panel of the type comprising at least a substrate and an upper layer provided on the substrate,
The top layer comprises a vinyl-based synthetic material layer,
Wherein said substrate is a wood-based substrate and a primer is provided between said substrate and said vinyl-based composite material layer. The method of claim 1,
Wherein said primer is associated with a polyurethane based dispersion adhesive. 3. The method according to claim 1 or 2,
Said vinyl-based composite material layer being associated with a PVC film. As a panel manufacturing method,
The panel is of a type comprising at least a substrate and an upper layer provided on the substrate, the upper layer comprising a thermoplastic synthetic material,
The method includes at least a first step in which the thermoplastic synthetic material is subjected to a first temperature and a first pressure, wherein a structure is formed in the thermoplastic synthetic material and the thermoplastic synthetic material is subjected to a second temperature and a second pressure. Receiving at least a second step, wherein the first temperature is higher than the second temperature and the second pressure is preferably higher than the first pressure. 5. The method of claim 4,
A consolidated package is formed before or in conjunction with the first step, wherein the package comprises at least a pattern and the thermoplastic composite material. The method according to claim 5 or 6,
And wherein said temperature in said first step is achieved at least 50 percent of the glass transition temperature of each thermoplastic composite material, expressed in degrees Celsius. 8. The method according to any one of claims 5 to 7,
In the first step, an infrared lamp is applied to generate the first temperature. 9. The method according to any one of claims 5 to 8,
In the second step, a structured press element is applied to generate the second temperature. 10. The method according to any one of claims 5 to 9,
In the second step, the thermoplastic layer is a panel manufacturing method, characterized in that the temperature is given between 20 ~ 55 ℃. A panel of the type comprising at least a substrate and an upper layer provided on the substrate,
The top layer comprises a pattern printed directly on the substrate and a layer of transparent or translucent synthetic material provided on the printed pattern,
Wherein said transparent or translucent synthetic material layer comprises vinyl and a primer is provided between said printed pattern and said vinyl-containing synthetic material layer. 11. The method of claim 10,
Wherein said primer comprises a polymer having aliphatic properties. 13. The method according to claim 11 or 12,
And said primer comprises polyurethane or polyisocyanurate. 13. The method according to any one of claims 10 to 12,
Said top layer being free of plasticizer. The method of claim 10 or 11,
Wherein said pattern is provided directly to said substrate, via one or more primer layers. 15. The method according to any one of claims 10 to 14,
And said pattern is printed by UV based ink. As a panel manufacturing method,
The panel is of a type comprising at least a substrate and an upper layer provided on the substrate,
The method comprises at least the following steps:
Preparing the substrate;
Performing printing on said substrate;
Providing a primer to the print; And
Providing a vinyl- or polyurethane-containing material to the substrate. As a panel manufacturing method,
The panel is of a type comprising at least a substrate and an upper layer provided on the substrate, wherein the upper layer comprises at least a synthetic material film,
The method includes at least providing the film to the substrate by press treatment at increased temperature. The method of claim 17,
The method further comprises at least providing a primer, preferably a polyurethane dispersion adhesive, to the substrate. The method according to claim 17 or 18,
And said substrate relates to a wood containing or wood based substrate. 20. The method according to any one of claims 17 to 19,
And said substrate comprises a foamed synthetic material. 21. The method according to any one of claims 17 to 20,
Said top layer comprises at least two synthetic material films, preferably airtight films. 22. The method of claim 21,
Said method comprising a step performed before said press treatment step, wherein in said preceding step said two composite material films are laminated with a laminated film. 23. The method according to any one of claims 17 to 22,
The press treatment is performed at a temperature between 80 and 150 ° C. 24. The method according to any one of claims 17 to 23,
And said press treatment is carried out with a pressing time shorter than one minute. As a panel manufacturing method,
The panel is of a type comprising at least a substrate and an upper layer provided on the substrate, wherein the upper layer comprises at least a printed pattern and a transparent or translucent synthetic material layer provided on the printed pattern,
The method includes at least providing a vinyl containing paste over the printed pattern to form at least a portion of the transparent or translucent synthetic material layer and providing relief to the transparent or translucent synthetic material layer by press treatment. Panel manufacturing method. The method of claim 25,
Wherein said paste relates to a PVC suspension in a plasticizer. 27. The method of claim 25 or 26,
And the paste is provided on the synthetic material film or the synthetic material layer having the printed pattern. The method of claim 27,
Wherein the layer of synthetic material comprises at least a backing layer and a composite material film, wherein the printed pattern is provided on the composite material film, and the backing layer and the composite material film are provided overlapping each other prior to providing the paste. A panel manufacturing method characterized by the above-mentioned. 29. The method according to any one of claims 25 to 28,
And after the paste is provided on the printed pattern, the top layer or an upper layer portion including the printed pattern is provided on the substrate. 30. The method according to any one of claims 25 to 29,
Before the press treatment, the paste is at least partially cured or gelled. 31. The method according to any one of claims 25 to 30,
And heat is supplied to the transparent or translucent layer by the press treatment. 32. The method according to any one of claims 25 to 31,
Wherein said transparent or translucent layer is substantially formed by said paste.